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IGNITION SYSTEMS
CONTENTS
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INDEX
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DIAGNOSTICS/SERVICE PROCEDURES
INDEX
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GENERAL INFORMATION (2) Connect the negative (-) voltmeter lead into the
This section of the group, Diagnostics/Service Proce- ground wire. For wire identification, refer to Group
dures, will discuss basic ignition system diagnostics 8W, Wiring Diagrams.
and service adjustments. (3) Set the voltmeter to the 15 Volt DC scale.
For system operation and component identification, 4.0L Engines: Remove distributor cap. Rotate
refer to the Component Identification/System Opera- (crank) engine with starter until pulse ring (Fig. 1)
tion section of this group. enters the magnetic pickup on camshaft position sen-
For removal or installation of ignition system com- sor. Distributor rotor should be pointed in 9 o’clock
ponents, refer to the Component Removal/Installation position. The movable pulse ring should now be
section of this group. within the sensor pickup.
For other useful information, refer to On-Board Di- 5.2L Engines: Remove coil high-tension cable and
agnostics in the General Diagnosis sections of Group
all spark plug cables at distributor cap. Note and
14, Fuel System in this manual.
mark position of cables before removal (Fig. 2). Re-
For operation of the DRB II Diagnostic Scan Tool,
move distributor cap from distributor (two screws).
refer to the appropriate Powertrain Diagnostic Proce-
Rotate (crank) the engine until the distributor rotor is
dures service manual.
pointed towards the rear of vehicle. The movable
AUTOMATIC SHUT DOWN (ASD) RELAY pulse ring should now be within the sensor pickup.
Refer to Relays—Operation/Testing in the Group
14, Fuel System section of this service manual.
DISTRIBUTOR ROTOR
Visually inspect the rotor (Figs. 10 or 11) for cracks, Fig. 8 Engine Firing Order—4.0L Engine
evidence of corrosion, or the effects of arcing on the ence noise suppression, will appear charred. This is
metal tip. Also check for evidence of mechanical inter- normal. Do not remove the
ference with the cap. Some charring is normal on the
end of the metal tip. The silicone-dielectric-varnish-
compound applied to the rotor tip for radio interfer-
Z IGNITION SYSTEMS 8D - 11
SENSOR RESISTANCE (OHMS) THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR
LOOSE FITTING CLOTHING.
CAUTION: When disconnecting a high voltage cable WARNING: SET PARKING BRAKE OR BLOCK THE
from a spark plug or from the distributor cap, twist DRIVE WHEELS BEFORE PROCEEDING WITH THIS
the rubber boot slightly (1/2 turn) to break it loose. TEST.
Grasp the boot (not the cable) and pull it off with a
steady, even force. (1) Unplug the ignition coil harness connector at
the coil (Figs. 17 or 18).
(1) Disconnect the ignition coil secondary cable
from center tower of the distributor cap. Hold the
cable terminal approximately 12 mm (1/2 in.) from a
good engine ground (Fig. 16).
(1) Disconnect the wire harness connector from the SENSOR RESISTANCE (OHMS)
sensor (Figs. 22 or 23).
COMPONENT REMOVAL/INSTALLATION
INDEX
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Automatic Shut Down (ASD) Relay .. . . . . . . . . . . 21 Intake Manifold Charge Air Temperature Sensor . . 29
Camshaft Position Sensor . . . . . . .. . . . . . . . . . . 21 Manifold Absolute Pressure (MAP) Sensor . . . . . . 29
Crankshaft Position Sensor . . . . . .. . . . . . . . . . . 22 Oxygen (O2) Sensor . . . . . . . . . . . . . . . . . . . . . . . 30
Distributor . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 25 Powertrain Control Module (PCM) . . . . . . . . . . . . . 30
Engine Coolant Temperature Sensor . . . . . . . . . . . 24 Spark Plug Secondary Cables . . . . . . . . . . . . . . . 32
General Information . . . . . . . . . . . .. . . . . . . . . . . 21 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ignition Coil . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 28 Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . 33
INSTALLATION—4.0L ENGINE
(1) Position the camshaft position sensor in the
distributor housing. Place the wire harness grommet Fig. 5 Camshaft Position Sensor—5.2L Engine
into the opening in the distributor housing. (5) Remove distributor rotor from distributor shaft.
(2) Install retaining arm and retaining screw. (6) Lift the camshaft position sensor assembly from
(3) Install distributor shaft into distributor hous- the distributor housing (Fig. 5).
ing. Make sure the upper thrust washer is installed
on the shaft. INSTALLATION—5.2L ENGINE
(4) Position thrust washer and drive gear on dis- (1) Install camshaft position sensor to distributor.
tributor shaft. Align sensor into notch on distributor housing.
(5) Note the previous CAUTION and install dis- (2) Connect wiring harness.
tributor drive gear roll pin. (3) Install rotor.
(6) Install rotor. (4) Install distributor cap. Tighten mounting
(7) Install distributor. screws.
(5) Install spark plug cables in correct firing order
REMOVAL—5.2L ENGINE
(Fig. 4) to distributor cap. Be sure all spark plug
Distributor removal is not necessary to remove
cables are firmly connected into distributor cap tow-
camshaft position sensor.
ers.
(1) Disconnect negative battery cable at battery.
(2) Remove coil high-tension cable and all spark
plug cables at distributor cap. Note and mark position
CRANKSHAFT POSITION SENSOR
of cables (Fig. 4) before removal. REMOVAL—4.0L ENGINE
(3) Remove distributor cap from distributor (two The crankshaft position sensor is mounted to the
screws). transmission bellhousing at the left/rear side of the
(4) Disconnect camshaft position sensor wiring har- engine block (Fig. 6).
ness from main engine wiring harness.
Z IGNITION SYSTEMS 8D - 23
INSTALLATION—4.0L ENGINE
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the two sensor mounting
bolts to 19 NIm (14 ft. lbs.) torque.
REMOVAL—4.0L ENGINE
The sensor is installed in the thermostat housing
(Fig. 10) on 4.0L engines.
INSTALLATION—5.2L ENGINE
(1) Install sensor.
(2) Tighten to 7 NIm (5.5 ft. lbs.) torque.
(3) Connect electrical connector to sensor.
The sensor connector is symmetrical (not indexed).
It can be installed to the sensor in either direction.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System.
DISTRIBUTOR
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable. The camshaft position
sensor is located in the distributor on all engines.
REMOVAL—4.0L ENGINE
(1) Disconnect the negative battery cable at the
battery.
(2) Scribe a mark on the distributor housing. Do
this below the left side of (past) the number one spark
plug cable post of the distributor cap. This will be Fig. 13 Mark Distributor Housing—4.0L Engine
used as a reference for number 1 cylinder firing posi-
tion (Fig. 13). with zero on front cover timing scale (Fig. 14).
(3) Remove the distributor cap. The timing mark is on the edge of vibration
(4) Turn the engine crankshaft in a clockwise direc- damper closest to engine timing chain cover.
tion until rotor is approaching scribe mark on dis- (5) Align the trailing edge of the rotor blade with
tributor housing. Then slowly turn engine until tim- the scribe mark on the distributor housing (Fig. 15).
ing mark on crankshaft vibration damper lines up
8D - 26 IGNITION SYSTEMS Z
REMOVAL—5.2L ENGINE
IGNITION COIL
The ignition coil is an epoxy filled type. If the coil is
replaced, it must be replaced with the same type.
REMOVAL—4.0L ENGINE
The ignition coil is mounted to the right side of the
4.0L engine block next to the distributor (Fig. 23).
INSTALLATION—5.2L ENGINE
(1) Install the ignition coil to coil bracket. If nuts
and bolts are used to secure coil to coil bracket,
tighten to 11 NIm (100 in. lbs.) torque. If the coil
mounting bracket has been tapped for coil mounting Fig. 26 Air Temperature Sensor—5.2L
bolts, tighten bolts to 5 NIm (50 in. lbs.) torque. Engine—Typical
(2) Connect all wiring to ignition coil.
(1) Disconnect electrical connector at sensor (Fig.
INTAKE MANIFOLD CHARGE AIR TEMPERATURE 26).
SENSOR (2) Remove sensor from intake manifold.
Fig. 27 MAP Sensor—4.0L Engine Fig. 29 MAP Sensor Rubber Fitting—5.2L Engine
INSTALLATION—4.0L ENGINE (2) Remove throttle body. Refer to Throttle Body
(1) Install sensor to cowl panel. Install 2 screws removal in the Group 14, Fuel System section of this
and tighten to 3 NIm (25 in. lbs.) torque. manual.
(2) Install the sensor vacuum supply hose. (3) Remove two MAP sensor mounting screws (Fig.
(3) Connect the sensor electrical connector. 29).
(4) While removing MAP sensor, slide the L-shaped
REMOVAL—5.2L ENGINE
rubber vacuum fitting (Fig. 29) from the throttle body.
The MAP sensor is located on the front of the
(5) Remove rubber fitting from MAP sensor.
throttle body (Fig. 28) if equipped with the 5.2L en-
gine. INSTALLATION—5.2L ENGINE
An L-shaped rubber fitting is used to connect the (1) Install L-shaped rubber fitting to MAP sensor.
MAP sensor to throttle body (Fig. 29).
(2) Position MAP sensor to throttle body while
guiding L-shaped rubber fitting over throttle body
fitting.
(3) Install MAP sensor mounting screws. Tighten
screws to 3 NIm (25 in. lbs.) torque.
(4) Install throttle body. Refer to Throttle Body in-
stallation in the Group 14, Fuel System section of this
manual.
(5) Install air intake tube.
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Remove the coolant reserve/overflow bottle (one
Fig. 28 MAP Sensor—5.2L Engine bolt and two nuts) (Fig. 31)
The throttle body must be removed from the intake (3) Loosen the 60-Way connector mounting bolt
manifold for MAP sensor removal. (Fig. 32).
(1) Remove air intake tube at throttle body. (4) Remove the electrical connector by pulling
straight back.
Z IGNITION SYSTEMS 8D - 31
SPARK PLUGS
5.2L ENGINE. Spark plug cable heat shields are
pressed into the cylinder head to surround each cable
boot and spark plug (Fig. 33). These shields protect
the spark plug boots from damage (due to intense
engine heat generated by the exhaust manifolds) and
should not be removed. After the spark plug cable has
been installed, the lip of the cable boot should have a
small air gap to the top of the heat shield (Fig. 33).
If removal of the heat shield(s) is necessary, remove
the spark plug cable and compress the sides of shield
for removal. Each shield is slotted to allow for
INSTALLATION
(1) Check the pins in the PCM 60-way electrical
connector for damage. Repair as necessary.
(2) Install PCM. Tighten three mounting bolts to 1
NIm (9 in. lbs.) torque.
(3) Engage 60-way connector into PCM. Tighten
connector mounting bolt to 4 NIm (35 in. lbs.) torque.
Fig. 33 Heat Shields—5.2L Engine
(4) Install coolant reserve/overflow bottle (Fig. 31).
8D - 32 IGNITION SYSTEMS Z
IGNITION SWITCH
INDEX
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GENERAL INFORMATION
The ignition switch is located in the steering col-
umn. The Key-In-Switch and Halo Light are integral
with the ignition switch. Refer to Group 8M for Key-
In-Switch and Halo Light diagnosis.
SPECIFICATIONS
GENERAL INFORMATION SPARK PLUG CABLE RESISTANCE
The following specifications are published from the
latest information available at the time of publica-
tion. If anything differs between the specifica-
tions found on the Vehicle Emission Control
Information (VECI) label and the following spec-
ifications, use specifications on VECI label. The
VECI label is located in the engine compartment.
SPARK PLUGS